Modular Facing for Building Construction

ABSTRACT

The present invention relates to a facing surface which can be applied on a building construction. The object of the inventions is to provide a facing surface for a building construction which is reliable, robust and weather resistant, and furthermore is easy to handle, easy to attach to a building construction and easy to maintain afterwards. The present invention addresses this by providing a facing panel system for building constructions, comprising:
         a facing panel, where the facing panel has an outer surface and an inner surface, a first and a second panel edge, where a first panel flange extends from said first panel edge and a second panel flange extends from said second panel edge, where said first panel flange and said second panel flange are extended in approximately the same direction, forming an inner groove which encloses said inner surface, where at least one panel attachment rail is arranged in the inner groove extending from said inner surface,   a mounting bracket comprising at least one bracket attachment rail, where a cross-section through at least one said facing panel is identical to a cross-section through said mounting bracket,       

     where said facing panel is capable of being attached to the mounting bracket, when said facing panel is arranged in an upside down inverted position relative to said mounting bracket, where the inner surface of said facing panel is facing said mounting bracket, where the panel attachment rail is capable of engaging the bracket attachment rail.

FIELD OF THE INVENTION

The present invention relates to a facing surface which can be applied on a building construction.

BACKGROUND OF THE INVENTION

Building constructions have facing surfaces, which over time need to be restored and/or rebuilt. A facing surface of a building construction may be exposed to tough weather conditions and/or environment, especially in the cities and near the shore. Impacts such as wind, rain, risk of damage and issues of pollution may damage the surface of a building construction. The facing surfaces will over time be worn and break. The repair and maintenance costs of a facing surface are expensive and time-consuming.

Also, the new building constructions are provided with a facing. The facing is often attached to the building construction using tools and fastening means. The construction of a building will take much man power and use of tools in situ. When the facing on the building needs to be replaced or repaired, the facing must be removed using much man power and tools.

In the art a number of cladding systems are known such as for example published in US2016/0230793, US20140290166, US20020166939, U.S. Pat. No. 6,113,201, DE4029967, FR 606844 or GB2352629.

Common for all these systems is that the actual outer cladding element is fastened to a backing panel, which in turn ay be fastened to a bracket on the outer wall. An example is disclosed in US 2016/0230793 wherein an intermediate panel has a cross-section, such that when the intermediate panel is fastened to the rear side of the actual cladding panel (a glass pane), the intermediate panel has downfacing “hooks”. The intermediate panel is thereafter arranged in an upside down position on the outer surface, such that the “hooks” are facing the opposite way. In this manner the combined intermediate panel and glass panel is mounted by the engagement of the “hooks”.

OBJECT OF THE INVENTION

The object of the inventions is to provide a facing surface for a building construction which is reliable, robust and weather resistant, and furthermore is easy and relatively cheaper to install and handle, easy to attach to a building construction and easy to maintain afterwards.

DESCRIPTION OF THE INVENTION

The present invention addresses this by providing a facing panel system for building constructions, comprising:

-   -   a facing panel, where the facing panel has an outer surface and         an inner surface, a first and a second panel edge, where a first         panel flange extends from said first panel edge and a second         panel flange extends from said second panel edge, where said         first panel flange and said second panel flange are extended in         approximately the same direction, forming an inner groove which         encloses said inner surface, where at least one panel attachment         rail is arranged in the inner groove extending from said inner         surface,     -   a mounting bracket, comprising at least one bracket attachment         rail, where a cross-section through at least one said facing         panel is identical to a cross-section through said mounting         bracket,

where said facing panel is capable of being attached to the mounting bracket, when said facing panel is arranged in an upside down inverted position relative to said mounting bracket, where the inner surface of said facing panel is facing said mounting bracket, where the panel attachment rail is capable of engaging the bracket attachment rail.

The facing panel has the benefits of being easy to handle, easy to attach to a building construction and easy to maintain afterwards. The facing panel may be provided in dif-ferent heights, widths and lengths according to the predefined application. The facing panel is provided with an outer surface with a predefined structure. The structure may be chosen according to the expectation defined for the building construction. The shape of the inner surface of the facing panel forms an inner groove. The inner groove provides an isolating effect when being mounted on the surface of the building construction. The facing panel may be arranged one by one on top of each other, and thereby provide a panel facing to the building construction.

With this configuration only one profile is needed in order to provide an complete fa-cade cladding system. The same profile in a reverse orientation acts as mounting bracket, whereafter it is possible to “hang” a similar panel upside down on the bracket.

The length of the facing panel may easily be cut using cutting tools, so the facing panel fits the surface of the building construction. The attachment rail or rails may be provided so that the facing panel is capable of an easy and quick releasable attachment to a mounting bracket provided on the building construction. The attachment rails may be arranged in relation to the inner surface of the facing panel and the releasable attachment to a mounting bracket is arranged in the inner groove. The attachment rails may also be angled such that they are not orthogonal to the rear side of the panel. In this manner when a panel is arranged on a bracket (inverted identical cross sections) the rails will slide on each other whereby the panel will be urged towards the mounting surface, en-suring a stable mount.

Surface roughness relates to the surface structure, for example the outer surface of the facing panel. The roughness of the surface of the aluminum may have an important role in determining how the facing surface will interact with the environment. For example, if the surface has a low roughness, almost smooth, the dirt will easily be washed off when it rains. If the surface has a high roughness, opposite smooth, the dirt will more likely stick to the surface of the facing panel. The expression of the entire facing surface may also be an issue when determining the roughness of the surface. The surface may also provide a plurality of architectural design possibilities and provide a controllable thermal impact on the building by using the facing panels. Furthermore, the facing panels may be provided with solar cells or similar.

In an advantageous embodiment of the invention, said facing panel has a longitudinal direction, where said first panel edge, second panel edge and said attachment rail are arranged parallel along the longitudinal direction.

The attachment rail or rails may be provided, so that the facing panel is capable of an agile releasable attachment to a mounting bracket. One or more mounting brackets may be fastened to the building construction. A plurality of mounting brackets and facing panels may be pre-assembled in a factory or assembled in situ. The mounting bracket may be arranged vertically and/or parallel to each other. Each mounting bracket may be provided with attachment rails. When the mounting brackets are assembled, the facing panels may be attached to the mounting brackets forming a facing structure. The mounting bracket or part of the mounting bracket may be produced from a material such as aluminium, aluminium alloy, stainless steel or wood etc.

In a further advantageous embodiment of the invention, a distal flange part of said first flange extends away from the inner groove.

The facing panel may be arranged in a vertical position, where the first flange is arranged upwards relative to the second flange, which is then arranged downwards. The distal flange part extends upwards and away from the first flange in a stump angle relative to the first flange. The distal flange may be arranged adjacent to a second flange of another overlying facing panel. The distal flange part and the first flange may provide an equivalent effect of an external sill, leading the water away from the wall of the building construction.

The inner surface of the first facing panel is facing mounting bracket, which may be a second facing panel arranged in an upside down inverted position relative to the pacing panel, and when the first panel edge of the first facing module is arranged adjacent to the second panel edge of the second facing panel, and the second panel edge of the first facing module is arranged adjacent to the first panel edge of the second facing panel, then the attachment rail of a first facing panel is capable of engaging the attachment rail of a second facing panel.

The mounting bracket may be provided by using a facing panel or panels, which are arranged in a backwards upside down position and fastened to the building construction or a lath frame, using screws, bolts and/or clips. The outer surface of the facing panel will then be facing the building construction, and the inner surface and the attachment rails will provide the function as mounting brackets.

The facing panel may be releasably attached to the upside down inverted facing panel using the attachment rails respectively arranged on both the facing panels. The two opposite facing panels may be arranged so that the inner surface of the first facing panel is facing the inner surface of the second facing panel, forming a cavity between them. The first panel edge of the first facing panel is arranged opposite to the second panel edge of the second facing panel, and the second panel edge of the first facing panel is arranged opposite to the first panel edge of the second facing panel. The one or more of the attachment rails of a first facing panel is capable of engaging one or more of the attachment rails of a second facing panel in a firm releasable locking grip.

In a further advantageous embodiment of the invention, at least one protrusion extends from the inner surface adjacent to said second panel edge.

The protrusion may be arranged along the first panel edge, second panel edge and/or the attachment rail, which all may be arranged parallel to the longitudinal direction. The protrusion provided on the inner surface on one facing panel may provide a function as a guideline for which another facing panel may rest on or next to. Furthermore the protrusion also acts as a self-locking feature as the distal end of the panel, in the mounted position, will be held in place by the engaging flanges, and at the same time the distal end will engage the protrusion, thereby making it difficult to move the panel upwards (and thereby loose from the mounting bracket). Likewise, the same protrusion when used on the bracket, will indicate the correct position for the lower edge of the panel.

The mounting bracket may be connected so that the distal flange edge provided on the second panel is arranged along the protrusion provided on the first facing panel and vice versa. The releasable locking grip provided between the two facing panels provides a firm attachment to each other.

In a further advantageous embodiment of the invention, the whole or part of said facing panel is manufactured from a material comprising aluminium or aluminium alloy.

The facing surface of a building construction may be exposed to tough weather conditions and/or environment. Impact such as wind, rain, risk of damage and issues of pollution may damage the surface of a building construction. The facing panel or part of the facing panel may be provided in a material such as aluminum or aluminum alloy. The facing panel made from aluminum or aluminum alloy may be chosen because the properties of aluminum are known to be corrosion resistant, robust and durable com-pared to other types of metal, such as steel and stainless steel etc. The properties of aluminum as a material, and the high-quality material of alloy from which the facing panels are manufactured, may assure a reliability and quality protection, in particular in adverse environmental conditions. An aluminum facing panel performs well in harsh environments and is sturdy, capable of withstanding high impact with a high malleable strength, and may therefore act as a building construction shield.

The facing panels may have a customized design or a standard design. The development and manufacturing of extruded aluminum profiles is quick and at a low costs.

In a still further advantageous embodiment of the invention, at least one lath comprises at least one panel attachment means, where a cross section of said panel attachment means is identical to the cross section of at least one of said bracket attachment rails.

A lath frame may be provided by using a plurality of laths. The laths may be provided with bracket attachment rails as panel attachment means for easy attachment of the facing panels. The lath comprising the panel attachment means may be manufactured from a material comprising aluminium or aluminium alloy. The facing module system comprising laths with panel attachment means may advantageously be pre-manufactured forming a facing area for a building construction.

In a further advantageous embodiment of the invention, at least one lath comprises at least one panel attachment means, where said panel attachment means is provided by at least one of said mounting brackets.

The facing module system comprises a pre-manufactured area of mounting bracket with a plurality of facing panels forming a facing area for a building construction. The mounting bracket may be fastened to the building construction before or after the facing panels are attached to the building construction. The predefined area of facing may be preassembled in a factory or assembled in situ as facing modules in a predefined size. The facing modules may easily be attached to the surface of the building construction, providing a new facing surface to the building construction.

Further flanges may be provided extending from the rear surface of the panel. These flanges may for example serve as distance keepers, such that further stability between the bracket and the panel is achieved.

The present invention also provides a method of attaching a facing on a building construction using said facing panel system according to claim 1, comprising the steps:

-   -   a) providing one or more mounting brackets, and     -   b) attaching said mounting bracket to said building         construction,     -   c) providing one or more facing panels, and     -   d) attaching said facing panels in an upside down inverted         position relative to said mounting bracket.

This invention describes an easy and fast method to provide a new facing surface for a building construction. Attaching a new facing on a building construction may be provided by using the facing module system. The facing module system may be assembled before being attached to the building construction or be assembled directly onto the surface of the building construction. One or more facing panels may be releasably attached to the mounting bracket using the panel attachment means provided on the mounting bracket.

Building constructions also have corners and/or curves where the panel endings of the facing panels may be provided with a transition cover between two panel endings. The transition cover may have a shape such as a corner or an end cover. The corner cover may be provided as a covering between two panel endings. The cover sides may be perpendicular in relation to each other and the cover sides may extend in each direction. The cover sides form an acute or an obtuse angle in relation to each other and the cover sides extend in each direction. The end cover may be provided in for example a U- or L-shape, so that the U- or L-shape fits over the edge of the facing panel.

The facing module system is easily attached to the building construction. The construction of the facing of the building will reduce the need for manpower. When the facing on the building needs to be replaced or repaired, the facing panels may be removed without using tools.

The invention has now been explained with reference to a few embodiments which have only been discussed in order to illustrate the many possibilities and varying design possibilities achievable with the facing panels and the facing module system according to the present invention.

DESCRIPTION OF THE DRAWING

The embodiments of the invention are described in the following with reference to:

FIG. 1 a,b : A perspective view of a facing panel.

FIG. 2 a,b : A cross-sectional view of a facing panel.

FIG. 3 a,b : A cross-sectional view of a facing panel, second edge connection.

FIG. 4 : A cross-sectional view of a first embodiment of facing panels mounted on a lath frame.

FIG. 5 : A cross-sectional view of a second embodiment of facing panels mounted on a lath frame.

FIG. 6 : A perspective view of a third embodiment of facing panels mounted on a lath frame.

FIG. 7 : A cross-sectional view of facing panel, end cover pieces.

DETAILED DESCRIPTION OF THE INVENTION

An embodiment of the invention is explained in the following detailed description. It is to be understood that the invention is not limited in its scope to the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways.

FIG. 1 shows a facing panel 1 from the front side, FIG. 1 a , and from the back side, FIG. 1 b . The facing panel 1 has an outer surface 2 and an inner surface 3, a first panel edge 4 and a second panel edge 5. The first flange 6 extends from the first panel edge 4. The second flange 7 extends from the second panel edge 5. The first flange 6 and the second flange 7 are extending in approximately the same direction, forming an inner groove 11 which encloses said inner surface 3. Three attachment rails 8 are arranged in the inner groove 11 extending from said inner surface 8. The attachment rails are capable of being realizably attached to panel attachment means provided on the building construction. A distal flange part 10 of said first flange 6 extends away from the inner groove 11. A protrusion 12 extends from the inner surface 3 adjacent to said second panel edge 5.

The facing panel 1 has a longitudinal direction X, where said first panel edge 4, second panel edge 5 and said attachment rails 8 are arranged parallel to the longitudinal direction X. The facing panel 1 may be provided with a predefined height, length and depth.

FIG. 2 illustrates in a cross-sectional view respectively a facing panel 1, FIG. 2 a , and two facing panels 1 attached to each other, FIG. 2 b.

In FIG. 2 a , a facing panel 1 has an outer surface 2 and an inner surface 3, a first panel edge 4 and a second panel edge 5. The first flange 6 extends from the first panel edge 4. The second flange 7 extends from the second panel edge 5. The first flange 6 and the second flange 7 are extended substantially in the same direction and thereby forming a u-shaped profile with an inner groove 11 which encloses said inner surface 3. Three attachment rails 8, two side rails 8 and one centre rail 9 are arranged in the inner groove 11 extending from said inner surface 3. The two side rails 8 are from a cross-sectional view substantially L-shaped and the centre rail 9 is from a cross-sectional view substantially T-shaped.

FIG. 2 b shows how two facing panels 1′,1″ are attached to each other, where one of the first facing panel 1′ is the mounting bracket. The first facing panel 1′ may for example be fastened to a surface on a building construction. The second facing panel 1″ is attached to the facing panel 1′, so that the second facing panel 1″ forms a facing surface on a building construction. The two facing panels 1′,1″ are arranged so that the inner surface 3 of the first facing panel 1′ is facing the inner surface 3 of the second facing panel 1″. The first panel edge 4′ of the first facing panel 1′ is arranged opposite to the second panel edge 5″ of the second facing panel 1″, and the second panel edge 5′ of the first facing panel 1′ is arranged opposite to the first panel edge 4″ of the second facing panel 1″. The two side rails 8′ and one centre rail 9′ of a first facing panel 1′ are capable of engaging the two side rails 8′ and one centre rail 9′ of a second facing panel 1″. The inner groove 11 provided in the first facing panel 1′ and the inner groove 11 provided in the second facing panel 1′ form a cavity, which has an isolating effect.

The two facing panels 1′,1″ are arranged correctly relative to each other, where the distal flange edge 10 provided on the second panel 1″ is arranged substantially adjacent the protrusion 9′ provided on the first facing panel 1′ and vice versa. One first side rail 8′ provided on the first facing panel 1′ is in a releasable locking grip with the centre rail 9″ provided on the second facing panel 1′, and one second side rail 8″ provided on the second facing panel 1″ is in a releasable locking grip with the centre rail 9′ provided on the first facing panel 1′. The releasable locking grip provided between the two facing panels 1′,1″ provides a firm grip onto the facing surface on the building construction.

FIG. 3 a,b shows a cross-sectional view of a facing panel second edge connection. When a plurality of facing panels is provided on a building construction, the facing panels are arranged end to end, extending the facing surface one by one.

FIG. 3 a shows two embodiments of an arrangement related to the second flange 7. In the first embodiment, the second flange 7 is arranged in a right angle 91 relative to the outer surface 2 of the facing panel 1. In the second embodiment, the second flange 7 forms an acute angle 91 relative to the outer surface 2 of the facing panel 1.

FIG. 3 b shows four facing panels 1 ¹, 1 ², 1 ³, 1 ⁴ which in this embodiment are arranged relative to each other. The two of the facing panels 1 ², 1⁴ provide the function of mounting brackets. The facing panel 1′ is provided with a protrusion 12′. The distal flange edge 10′ provided on the facing panel 1 ² is arranged substantially adjacent to the protrusion 12′ provided on the first facing panel 1′. The second flange 7′ of the first facing panel 1 ⁴ is arranged substantially adjacent to the distal flange edge 10′ provided on the facing panel 1 ² and the protrusion 12′ provided on the first facing panel 1′.

The distal flange edge 10″ provided on the facing panel 1 ³ is arranged substantially adjacent to the protrusion 12″ provided on the first facing panel 1 ⁴. The second flange 7″ of the first facing panel 1′ is arranged substantially adjacent to the distal flange edge 10″ provided on the facing panel 1 ³ and the protrusion 12″ provided on the first facing panel 1 ⁴.

FIG. 4 shows a cross-sectional view of a first embodiment of three facing panels 1 ¹, 1 ², 1³ mounted on a lath frame. The mounting bracket lath is attached to a building construction. The mounting bracket lath may be arranged vertically and parallel to each other. The facing panels 1 ¹, 1 ², 1 ³ are arranged perpendicular to the mounting bracket lath 14. Each mounting bracket lath 14 is provided with panel attachment means 13, such as a predefined number of catches or hooks. The mounting bracket lath 14 may be an aluminium lath. The side rails 8 and centre rails 9 of the facing panels 1 ¹, 1 ², 1 ³ are capable of hooking on to the panel attachment means 13, which provide a releasable locking grip. The facing panels 1′,1 ², 1 ³ are then firmly attached to the facing surface on the building construction.

FIG. 5 shows a cross-sectional view of a second embodiment of facing panels mounted on a lath frame. The mounting brackets attached to a lath 15 may be arranged parallel to each other. The mounting brackets are facing panels, which are arranged in upside down inverse position perpendicular to the lath 15. The mounting brackets and/or the laths 15 are fastened to the building construction using fastening means 16, such as screws.

FIG. 6 shows a perspective view of a third embodiment of facing panels mounted on a lath frame. The facing module system comprises at least one facing panel. The facing panels 1 ¹, 1 ², 1 ³ . . . 1N are arranged relative to each other one by one, forming a facing surface on the building construction. The facing panels 1 ¹, 1 ², 1 ³ . . . 1N are releasably attached one by one to the inner facing panels as explained in FIG. 2 b and FIG. 3 b.

The method of attaching a facing module system comprising facing panels and mounting brackets on a building construction 17 is carried out by providing one or more laths 15. The laths 15 are fastened to a building surface, and the mounting brackets are attached to the laths 15. The facing panels 1′,1 ², 1 ³ . . . 1N are releasably attached to the mounting brackets using the panel attachment means provided on the mounting brackets.

FIG. 7 shows a cross-sectional view of facing panel end cover pieces. The corner cover may be provided as a cover, where the cover sides are perpendicular and extend in each direction, where a first and a second facing module system comprise a plurality of facing panels 1′,1″ which are arranged on each side of a corner, arranged perpendicular to each other. FIG. 7 a shows an embodiment where parts of the cover sides of the corner cover 17 cover parts of the outer surfaces of the facing panels 1′,1″. FIG. 7 b shows an embodiment where parts of the cover sides of the corner cover 18 are bended so that parts of the cover sides of the corner cover 18 are arranged between the building construction and the facing panels 1′,1″. 

1. Facing panel system for building constructions, comprising: a facing panel (1), where the facing panel (1) has an outer surface (2) and an inner surface (3), a first and a second panel edge (4,5), where a first panel flange (6) extends from said first panel edge (4) and a second panel flange (7) extends from said second panel edge (5), where said first panel flange (6) and said second panel flange (7) are extended in approximately the same direction, forming an inner groove (11) which encloses said inner surface (3), where at least one panel attachment rail (8) is arranged in the inner groove (11) extending from said inner surface (3), a mounting bracket (1′), comprising at least one bracket attachment rail, where a cross-section through at least one said facing panel (1) is identical to a cross-section through said mounting bracket (1′), where said facing panel (1) is capable of being attached to the mounting bracket (1′), when said facing panel (1) is arranged in an upside down inverted position relative to said mounting bracket (1′), where the inner surface (3) of said facing panel (1) is facing said mounting bracket (1′), where the panel attachment rail (8) is capable of engaging the bracket attachment rail (8′).
 2. Facing panel system according to claim 1, where said facing panel has a longitudinal direction, where said first panel edge, second panel edge and said attachment rail are arranged parallel to the longitudinal direction.
 3. Facing panel system according to claim 1, where a distal flange part of said first flange extends away from the inner groove.
 4. Facing panel system according to claim 1, where at least one protrusion extends from the inner surface adjacent to said second panel edge.
 5. Facing panel system according to claim 1, where the whole or part of said facing panel is manufactured from a material comprising aluminium or aluminium alloy.
 6. Facing module system according to claim 1, where at least one lath comprises at least one panel attachment means, where a cross section of said panel attachment means is identical to the cross section of at least one of said bracket attachment rails.
 7. Facing module system according to claim 1, where at least one lath comprises at least one panel attachment means, where said panel attachment means is provided by at least one of said mounting brackets.
 8. Method of attaching a facing on a building construction using said facing panel system according to claim 1, comprising the steps: a) providing one or more mounting bracket, and b) attaching said mounting bracket to said building construction, c) providing one or more facing panels, and d) attaching said facing panels in an upside down inverted position relative to said mounting bracket. 